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INSTALLATION AND MAINTENANCE MANUAL

U-MAD® TMA

NCHRP 350 TL-2 and TL-3 Truck Mounted Attenuator

Lindsay Transportation Solutions Sales and Services, Inc (888) 800-3691 [U.S. toll free] or +1 (707) 374-6800 Lindsay Transportation Solutions Sales and Services, Inc (888) 800-3691 [U.S. toll free] or +1 (707) 374-68002

Step 1 Place the cartridge crate in an open area that will allow for access all the way around the crating. When the cartridge is being moved a fork lift with 6 ft. (2m) fork extension should be used so as not to damage the cartridge. Only lift from marked points on the crate.

Introduction

The U-MAD system packaging consist of a large crate which holds the TMA Cartridge and a second pallet which holds the L-Lift and a box of additional components.

Contact Information

If you need additional information, or have questions about the U-MAD TMA, please call the Lindsay Trans-portation Solutions Customer Service Department at (888) 800-3691 (U.S. toll free) or (707) 374-6800.

Address: Lindsay Transportation Solutions Sales and Services, Inc. 180 River Road Rio Vista, CA 94571 www.BarrierSystemsInc.com email: [email protected]


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www.BarrierSystemsInc.com

Lindsay Transportation Solutions Sales and Services, Inc (888) 800-3691 [U.S. toll free] or +1 (707) 374-6800 3

Step 2 Carefully remove the plywood shell using a crowbar and hammer.

Step 3 Carefully remove padded lumber from around the car-tridge. Do not pry against the cartridge as this will cause denting and scratching which will impede crash performance.

If necessary, use an automotive grade polishing compound to lift minor scratches

Step 4 Once the cartridge is uncrated , remove the box of ad-ditional components and verify inventory of that box. The box will contain electrical controls, two decals to be placed in the cab of the truck as reminders for proper operation, and hardware for mounting unit to the truck (ie. bolts, brackets).

Step 5 Once verification and uncrating of Cartridge, L-Lift, and Hardware, please proceed to the Mounting Instructions in the installation manual.

U-MAD® TMA

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Lindsay Transportation Solutions Sales and Services, Inc (888) 800-3691 [U.S. toll free] or +1 (707) 374-6800



Table of Contents

Introduction………………………………………………….

Contact Information …………………………………….

Safety Instructions …………………………………………..

Required Installation Tools ………………………………

Installation Mounting Instructions ……………………

Operating Instructions ……………………………………..

General Maintenance and Adjustments …………..

Repair Policy / Limited Warranty ……………………..14

4

4

4

6

7

12

12

Appendix

A. Mountings………………………………………………… 15

B. Diagrams for Electric Lighting, Connectors 16

C. Diagrams, Drawings for Hydraulics & Controls

U-MAD® TMA

20


U-MAD® Installation and Operations Manual


Introduction

The U-MAD Truck Mounted Attenuator (TMA) offers outstanding perfomance, excellent life cycle costs and quick, simple refurbishment. The U-MAD TMA is available in various sizes for workzones with speed capacities from 45 mph to 62 mph (70 km/h to 100 km/h) to supply a wide range of protection for workers, motor-ists and equipment. The TMAs are designed to absorb collision energy during rear-end impacts, prevent impacting vehicles from underriding the truck and reducing expensive damage to equip-ment.

The system offers many flexible options in lifts, mounting systems, hydraulics, and controllers to make installation, use, and maintenance as simple and cost-effective as possible.

Applications for the U-MAD TMA include station-ary and slow-moving operations such as strip-ing, sweeping, marking, road plowing, and road-side maintenance operations such as repairing crash cushions, guardrails, and road surfaces.

Contact Information

If you need additional information, or have questions about the U-MAD TMA, please call the Lindsay Transportation Solutions Customer Service Department at (888) 800-3691 (U.S. toll free) or (707) 374-6800.

Address: Lindsay Transportation Solutions Sales and Service 180 River Road Rio Vista, CA 94571

www.BarrierSystemsInc.com email: [email protected]

Safety Instructions

The TMA support structure and cartridge should be rigidly attached to the frame rails of the truck, after the support vehicle has been prop-erly equipped with ballast and counterweights (if needed) to meet its’ fully designated weight (including amenities such as an arrow panel). The cartridge must be a minimum of 11” (280 mm) and a maximum of 13” (330 mm) from the ground and level when in the full-down position. The U-MAD TMA must be in the full-down posi-tion whenever the unit is “in service” as either a parked protection device or as a moving protec-tive shadow vehicle.

• All personnel should stand clear of the TMA before a qualified operator raises or lowers it.

• Lock pins must be in place when the TMA is in the travel (up) position or when trav-eling more than 5 miles (8 km).

• When traveling less than 5 miles with the TMA in the up position without the pins inserted, the maximum speed should not exceed 25 mph (40 km/h).

• The maximum speed in the deployed (down) position should not exceed 25 mph (40 km/h).

• Caution must be observed when attaching or detaching the TMA cartridge. Never attempt to use the force of the hydraulic power mechanism to align the pins or bolts.

• Never stand, sit, or place any objects onto a lowered U-MAD TMA. The top of the TMA should never be used for a work surface.

• Safety warning labels have been provided for the cab of the truck and the area where the control box is being mounted on the outside of the truck. Always have a qualified operator that is familiar with all of the warning labels located through-out the lift and cushion areas.

http://www.barriersystemsinc.com/



Installation Mounting Instructions

All welding, drilling, and/or bolt work should be accomplished and inspected by a qualified me-chanic and a certified welder.

It is recommended that the U-MAD TMA be mounted to a truck weighing between 19,000 lbs. (8,618.4 kg) and 20,000 lbs. (9,072.0 kg) to achieve the proper NCHRP 350 impact perfor-mances.

It is recommended that any additional perma-nent weight that will normally be on the vehicle should be added at this time (prior to TMA in-stallation). If this step is neglected, the weight added after the TMA is installed may cause the TMA to be too close to the ground and out of specification.

STOP: If you are installing an optional mount-ing system, refer to the installation instructions included in your shipment. If the installation in-structions are missing, contact your local distrib-utor or a BSI customer service representative.

Step 1: Inspect the shipped materials

1.1 Inspect the U-MAD TMA at the time of receipt and note any shipping damages on the carrier truck driver’s bill of lading. Have the notation initialed by the driver and subsequently report the damages to your BSI authorized Dis-tributor. 1.2 Remove the parts list from the sealed pack-age and assure that all of the parts listed are present. Report any missing parts to your Dis-tributor immediately.

Step 2: Unpack the materials

2.1 Cautiously remove the protective shipping material from the TMA support structure.

2.2 Cautiously remove the protective shipping materials from the UMAD Cartridge.

2.3 The following items will be needed to mount the TMA support structure to the vehicle:

(10) each - 3” x ¾” (76 mm x 19 mm), Grade 8 hex head bolts with washers and nuts.

(2) each - 4” x 36” C-channels (102 mm x 914 mm) or at a minimum, (2) each 3” x 3” x 36” x ¼” angle iron ( 30 mm X 30 mm X 360 mm X 2.5 mm).

Electrical cable with a minimum diameter of 5/16” (0.80 cm) or 1/0 cable for power to the hydraulics.

(2) each - jack stands to support the rear of the TMA.

U-MAD® TMA



In the cab of truck, a safety label should be clearly visible by the driver at all times that states when using a 100k TMA : “TOTAL TRAVEL HEIGHT 12’ 6” ( 3.8 meters), “AVOID ALL CURBS, MEDIANS, AND OFF ROAD AREAS WITHOUT ELEVATING CUSHION MINIMUM OF 15°”, and “WHEN CUSHION IS IN UP (travel) POSITION, LOCKING PINS MUST BE IN WITH COTTER PIN THROUGH END”.

Required Installation Tools

Standard mechanics tools are required to install the U-MAD TMA. These tools include, but are not limited to:

1. Lifting device (standard fork lift with fork ex-tensions)

2. Side cutters 3. Wire crimpers 4. 3 lb. + hammer 5. Drill (able to penetrate 3/8” steel) 6. Drill bits 7/8” with starter bits 7. 2 ea. 1 1/2” wrench or socket 8. 2 ea. 1 1/8” wrench or socket 9. Tape measure 10. 24” + carpenters level 11. Plumb bob and line

Note: In the event that welding is required, use only a certified welder.

Optional Installation Tools

These tools while not required have proven to aide in the ease of installation on the U-MAD TMA.

1. Large clamps (C-clamp, Bessie clamp, etc…) 2. Hand bar or crow bar 3. Electromagnetic drill 4. Multi-meter



Level

23.5 in. (597 mm)


3.5 Adjust the Support Structure Adjust the position of the Support Structure so that it is level and the distance from the ground to the top of the support structure tubes is 23.5 in. (597 mm). Mark the attachment holes for drilling (Figure 4).

3.6 Drill Holes After the Support Structure is level and at the correct height, mark and drill (4) 7/8 in. (22 mm) holes (Figure 5). Refer to drawing 1, notation A, in the Appendix .

3.7 Bolt Assembly Bolt the Support Structure assembly to the frame using (2 each per side) 3” x .75” (76 mm x 190 mm) grade 8 bolts, using washers, lock washes and nuts (Figure 6). Torque the bolts to 145 – 150 ft. lbs. (197 -203 Newton meters).

Figure 4. Adjust level and height of the Support Structure.

Figure 5. Drill holes through the frame rails.

Figure 6. Bolt the support structure.

U-MAD® TMA




3.8 Install Side Channel Braces Position the Channel Braces on the truck frame insuring that the channels extend out even with, or past the rear of the support vehicle at a 45 degree angle to the lower section of the lift sys-tem as noted in drawing 1, notation B in Appen-dix (Figure 7).

3.9 Bolt the Channel Braces Bolt the Chan-nel Braces to the truck frame insuring that the channels extend out even with or past the rear of the support vehicle at a 45 degree angle to the lower section of the lift system (Figure 8). Refer to drawing 1, notation B, in the Appendix. Torque the bolts to 145 – 150 ft. lbs. (197 -203 Newton meters)

Note: The support truck should already be loaded to its final adjusted weight prior to mounting the U-MAD TMA.

3.10 Route Control Wires It is recommended that wiring be fed to the rear of the truck to accept the 7 round, or 4 flat, plug supplied to connect the vehicles lights to the U-MAD TMA to run the taillights, travel lights, 3 light bars and any accessories.

3.11 Route Power Source A secondary electrical power source (+) will need to be provided to the electrical/hydraulic lifting pump (minimum cable diameter of 5/16” (8.0 mm) or 1/0 cable).

Refer to Appendix C for proper wiring diagram for different hydraulic systems.

Figure 7. Install side Channel Braces.

Figure 8. Bolt the side Channel Braces.


U-MAD® TMA


3.12 Pick up the TMA Using a standard duty forklift with fork exten-sions, carefully transfer the TMA to the back of the truck to for installation.

3.13 Attach TMA to Support Structure Attach the U-MAD cartridge to the Support Structure using the (2) 1” x 6” (25.4 mm x 152 mm) bolts and nuts provided. (Figure 10 – 11) Refer to drawing 1, notation D in the Appendix.

3.14 Fill hydraulic oil Fill the hydraulic pump reservoir with AW45 clear, non foaming hydraulic fluid.

Note: During the manufacturing process of the unit the hydraulic fluid has been added to the system and the system has been cycled to remove any air from the system.

Figure 9. Transport the TMA.

Figure 10. Bolt the TMA to the Support Bracket.

Figure 11. Fully attached TMA.



3.15 Attach Cylinder

3.16 Connect Plug

3.17 Connect Power

Attach lift cylinder to the cartridge using the 1” pin (2.54 cm) provided (Figure 12).

Connect the quick disconnect 4 flat or 7 round plug from the truck to the 4 flat or 7 round plug from the cartridge and test the lighting (Figure 13).

Refer to Appendix B for proper wiring diagram.

Connect the power cable to the motor (Figure 14). Be sure that the power source is not energized before making this connection.

NOTE: Power and grounding of the hy-draulic power unit motor must be done in accordance with the truck manufacturer’s specifications and recommendations for supplying auxiliary power to accessories. Some vehicles have complex electronic and/or computer control systems that must be considered and integrated when provid-ing power to accessories. It is recommend-ed that a 200 amp in-line fuse or breaker is used on the power cable. This will reduce the potential for power unit failure or dam-age to the TMA or host vehicle.

Figure 12. Install the lift cylinder.

Figure 13. Plug in the quick disconnect.

Figure 14. Attached to Support Structure.




3.18 Level the CartridgeUsing the adjusters, level the entire U-MAD TMA cartridge to between 11” (279 mm) and 13” (330 mm) off of a level ground surface (Figure 15).

3.19 Wiring the Control BoxUsing the diagrams in Appendix C, properly wire the CAB / BED control box or boxes. Please take note of the hydraulics on your active system.

There are two types of hydraulics; standard and locking. Ensure to wire the system using the ap-propriate diagram in Appendix C.

Figure 15. Adjust the level of the cartridge.

U-MAD® TMA



Operating Instructions: 2. Caution! Stand clear of all moving parts Raising and Lowering the TMA

Raising the U-MAD TMA:

1. Caution! Stand clear of all moving parts while unit is moving.

2. Move the momentary three-way switch to the “Raise” position.

3. When the unit makes contact with the sup-port structure tubes, install the two (2) 3/4” (19 mm) safety locking pins from the storage tubes (see drawing 1, notation E) into the full lockup position tubes and install cotter pins through safety locking pins (see drawing 1, notation F in Appendix)

Lower the U-MAD TMA:

1. Remove the two (2), 3/4” (19 mm) safety locking pins from the lock up tubes and place in the storage tubes on the sides of the support structure (see drawing 1, notation E and F in Appendix)

Table 1. Maintenance Schedule.

while unit is moving.

3. Move the momentary three-way switch to the “Lower” position.

4. When the U-MAD TMA approaches the full-down position, toggle the switch on/off quickly to make sure the unit rests properly against the sup-port structure arms and adjusters.

IMPORTANT NOTE: It is recommended that the U-MAD TMA be placed into the full down position when the unit is being used as a shadow vehicle for a moving operation or a parked protection device. The car-tridge is not intended to be driven extensive miles at highway speeds in the full-down position and 25 mph is the maximum recommended speed when unlocked and in the down position.

If the need arises to move the unit through a highway median with steep up and down grades or to navigate through steep driveways or turn in or turn outs. It is recommended that the U-MAD TMA be elevated at least 15° while the obstacle is being circumvented.


General maintenance and Adjustments Interval

1. Check tightness of bolts, fasteners and locking pins Weekly

2. Oil swivel jack pivot points Monthly

3. Check hydraulic pump fluid Weekly

4. Change hydraulic pump fluid (AW46 Clear Hydraulic) Quarterly

5. Add hydraulic fluid (non-foaming clear hydraulic oil) As Needed

6. Grease hinge point between cartridge and support structure Quarterly

7. Clean exterior of hydraulic pump As Needed

8. Check and clean hydraulic ram Weekly

9. Clean working parts of suppor t structure (dirt, salt, oil, etc.) As Needed

10. Check U-MAD TMA for level and height of cartridge from ground Weekly

11. Check all friction points for lubrication Weekly

12. Check hydraulic system and clean Weekly


U-MAD® Installation and Operations Manual IMPORTANT NOTE: DO NOT POWER WASH OR USE HARMFUL CHEMICALS ON CARTRIDGE OR SUPPORT STRUCTURE. EXCESSIVE PRESSURE OR CHEMICALS COULD CAUSE PAINT TO PEAL OR WEAR PREMATURELY.

MINOR ADJUSTMENTS

NOTE: The U-MAD electric/hydraulic system provides power to raise and lower the TMA to the full up and deployed (down) positions. The needle control valve has been set at the factory to provide for a slow safe lowering time, you may experience greater speeds deploying the cushion until air is extracted from the cylinder; This speed should be checked before putting the unit into service and periodically from then on during the life of the U-MAD TMA.

NOTE: It may sometimes become necessary to adjust the in-line hydraulic oil needle control valve to speed up or slow down the decent of the TMA cartridge. To increase speed: loosen control screw jam nut and turn the control screw _ turn counter clockwise ---continue making _ turn adjustments until desired speed is achieved. Re-tighten the control screw jam nut. To decrease speed: reverse above direction (i.e. clockwise).

The initial factory setting is a 1 full counter clock-wise turn from a slightly seated position. Temper-ature when set was 75 degrees Fahrenheit and rising.

CAUTION . . . if the jam nut was loosened to ad-just, it must be re-tightened before normal usage is instituted.

After on site testing of the full-up, full-down opera-tion of the TMA, smooth operation of the lock-up pins should be checked. The pins were checked and adjusted at the factory but to avoid any field prob-lems, it is advised that they be rechecked.

U-MAD® TMA



Repair Policy / Limited Warranty

LIMITED WARRANTY

Lindsay Transportation Solutions, Inc. “LTS” (formerly Barrier Systems ) has tested the impact performance of its barriers and crash cushion systems, and other highway safety hardware under controlled conditions, however, LTS does not repre-sent nor warrant that the results of those con-trolled conditions would necessarily avoid injury to persons or property. LTS EXPRESSLY DISCLAIMS ANY WARRANTY OR LIABILITY FOR CLAIMS ARIS-ING BY REASONS OF DEATH OR PERSONAL INJURY OR DAMAGE TO PROPERTY RESULTING FROM ANY IMPACT, COLLISION OR HARMFUL CONTACT WITH THE PRODUCTS OR NEARBY HAZARDS OR OB-JECTS BY ANY VEHICLE, OBJECTS OR PERSONS.

LTS warrants that any product or component part manufactured by LTS will be free from defects in material or workmanship. LTS will replace free of cost any Product or component part manufactured by LTS that contains such a defect.

THE FOREGOING WARRANTY IS IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES NOT EX-PRESSLY SET FORTH HEREIN, WHETHER EXPRESS OR IMPLIED BY OPERATION OF LAW OR OTH-ERWISE, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

LTS’ LIABILITY UNDER THIS WARRANTY IS EX-PRESSLY LIMITED TO REPLACEMENT FREE OF COST (IN THE FORM AND UNDER THE TERMS ORIGINALLY SHIPPED), OR TO REPAIR OR TO MANUFACTURE BY LTS, PRODUCTS OR PARTS NOT COMPLYING WITH LTS SPECIFICATIONS, OR, AT LTS’ ELECTION, TO THE REPAYMENT OF AN AMOUNT EQUAL TO THE PURCHASE PRICE OF SUCH PRODUCTS OR PARTS, WHETHER SUCH

CLAIMS ARE FOR BREACH OF WARRANTY OR NEGLIGENCE. LTS SHALL NOT BE LIABLE FOR ANY INCIDENTAL, CONSEQUENTIAL OR SPE-CIAL LOSSES, DAMAGES OR EXPENSES OF ANY KIND, INCLUDING, WITHOUT LIMITATION, ANY SUCH LOSSES, DAMAGES OR EXPENSES ARIS-ING DIRECTLY OR INDIRECTLY FROM THE SALE, HANDLING OR USE OF THE PRODUCTS FROM ANY OTHER CAUSE RELATING THERETO, OR FROM PERSONAL INJURY OR LOSS OF PROFIT.

Any claim by the Buyer with reference to Products sold hereunder for any cause shall be deemed waived by the Buyer unless LTS is notified in writing, in the case of defects apparent on visual inspection,within ninety (90) days from the deliv-ery date, or, in the case of defects not apparent on visual

inspection, within twelve (12) months from the said delivery date. Products claimed to be defec-tive may be returned prepaid to LTS’ plant for inspection in accordance with return shipping instructions that

LTS shall furnish to the Buyer forthwith upon re-ceipt of the Buyer’s notice of claim. If the claim is established, LTS will reimburse that Buyer for all carriage costs incurred hereunder.

The forgoing warranty benefits shall not apply to (i) any Products that have been subject to improper storage, accident, misuse or unauthor-ized alterations, or that have not been installed, operated and maintained in accordance with approved procedures and (ii) any components manufactured by the Buyer.

W030587 Rev. 8 revised February 4, 2013



Appendix A - Mounting


U-MAD mounting utilizing the optional Support Structure bolted to truck frame. Shows one (1) of two (2) adjustable bolts (C) used to final adjust the height of the crash cushion.

Drawing 1. Support Structure .



Appendix B - Wiring Diagrams for Electric Lighting, Connectors

Electric wiring for the U-MAD Cartridge was completed by the factory. The electric wiring harness has been pre-installed.

However, to match the connection plug on the host vehicle, you may need to adjust the wiring on the receiving plug.

The wiring diagram in the Appendix will assist you in achieving proper wiring for your TMA.

All work should be accomplished and inspected by a qualified mechanic with experience in electrical & hydraulic systems.

DRAWINGS Cartridge Wiring DiagramDWG# 1430020 17

7-Pin Round Connector DWG# 1422030 18

7-Pin Spade Connector DWG# B100104 19


U-MAD® TMA

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Appendix C - Wiring Diagrams, Drawings for Hydraulics & Controls

The wiring of the hydraulic system and control boxes was completed by the factory. In order to operate the TMA, power and grounding of the hydraulic power unit motor must be done in accordance with the host vehicle manufacturer’s specifications and recommendations for supplying auxiliary power to accessories. Some vehicles have complex electronic and/or computer control systems that must be considered and integrated when providing power to accessories. It is recommended that a 200-amp in-line fuse or breaker is used on the power cable. this will reduce the potential for power unit failure or damage to the TMA or host vehicle.

In addition, the control box must be properly wired to the hydraulic power unit per the wiring diagrams found in the Appendix.

Prior to wiring, identify what hydraulic system is on the unit. There are two different systems; standard hydraulics and locking hydraulics.

All work should be accomplished and inspected by a qualified mechanic with experience in electrical & hydraulic systems.

DRAWINGS Standard HydraulicsDWG# 1429840 21

Cab Control | Standard HydraulicsDWG# 1422210 23

Bed Control | Standard Hydraulics DWG# 1422220 24

Lockout HydraulicsDWG# 1429850 25

Cab Control | Lockout HydraulicsDWG# 1422240 27

Bed Control | Lockout Hydraulics DWG# 1422250 28


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U-MAD® TMA


U-MAD® TMA

Page Left Intentionally Blank


U-MAD® TMA


Lindsay Transportation Solutions Sales and Services, Inc 180 River Road • Rio Vista, CA 94571 • +1 707.374.6800 U.S. Toll Free: 888.800.3691 • www.barrriersystemsinc.com

Installation manual details for the U-MAD TMA are subject to change without notice to reflect improvements and upgrades.Additional information is available from Lindsay Transportation Solutions Sales and Service © Lindsay Transportation Solutions

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